Automated Sanding System

ABSTRACT

A method and apparatus for sanding a number of surface features on a surface of an object. A first type of operation may be performed on the number of surface features on the surface of the object using a first end effector. Feedback laser data may be generated about the number of surface features after the first type of operation has been performed using a laser device. A second type of operation may be performed on the number of surface features using a second end effector and the feedback laser data to rework the number of surface features until the number of surface features has been reworked to within selected tolerances.

BACKGROUND INFORMATION

1. Field

The present disclosure relates generally to sanding operations and, inparticular, to an automated sanding system for performing these sandingoperations. Still more particularly, the present disclosure relates toan automated sanding system for sanding surface mismatches on thesurfaces of objects.

2. Background

In the manufacturing of certain objects, undesired surfaceinconsistencies may sometimes be created on the surfaces of theseobjects. As one illustrative example, milling operations performedduring the manufacturing of a wing for an aircraft may result inout-of-tolerance surface inconsistencies. A milling operation is amachining operation that removes material from a workpiece. Thisoperation may be performed by, for example, without limitation, cuttingmaterial away from the workpiece, cutting slots into the workpiece,threading, routing, planning, drilling, and/or performing other types ofcutting operations.

Milling operations may be performed using a milling machine. A millingmachine may include one or more cutting tools. A cutting tool may beused to remove material from an object while the cutting tool is movedrelative to the object. In some cases, a surface feature is created onthe surface of the object after this operation is performed. Thissurface inconsistency may be referred to as a “mismatch,” a “surfacemismatch,” or a “cutter mismatch.” The mismatch may take the form of,for example, without limitation, a raised edge, a sharp edge, or someother type of surface mismatch. The mismatch may be the result of, forexample, a step-over in the direction of travel. As another example, themismatch may be the result of the cutting tool replacing another cuttertool.

When a mismatch is outside of selected tolerances, the mismatch needs tobe reworked to within the selected tolerances. For example, the mismatchmay need to be sanded down to within selected tolerances. This sandingoperation may also be referred to as “blending” the mismatch with therest of the surface of the object. The blending of a mismatch with asurface is typically performed using a manually-operated sanding device.However, using a manually-operated sanding device to blend multiplemismatches may be more time-consuming and labor-intensive than desired.Additionally, the quality of the blending of multiple mismatches may beless consistent than desired when performed manually.

Further, depending on the shape, size, and type of object on which thesemismatches are located, manually blending these mismatches with thesurface of the object may be ergonomically difficult for a humanoperator. For example, using a manually-operated sanding device maycause ergonomic issues with respect to the hands, wrists, arms,shoulders, and/or back of the human operator operating the sandingdevice. Therefore, it would be desirable to have a method and apparatusthat take into account at least some of the issues discussed above, aswell as other possible issues.

SUMMARY

In one illustrative embodiment, a method may be provided. A first typeof operation may be performed on a number of surface features on asurface of an object using a first end effector. Feedback laser data maybe generated about the number of surface features after the first typeof operation has been performed using a laser device. A second type ofoperation may be performed on the number of surface features using asecond end effector and the feedback laser data to rework the number ofsurface features until the number of surface features has been reworkedto within selected tolerances.

In yet another illustrative embodiment, an apparatus may comprise afirst end effector, a laser device, and a second end effector. The firstend effector may be configured to perform a first type of operation on anumber of surface features on a surface of an object. The laser devicemay be configured to generate feedback laser data about the number ofsurface features after the first type of operation has been performed.The second end effector may be configured to perform a second type ofoperation on the number of surface features using the feedback laserdata to rework the number of surface features until the number ofsurface features has been reworked to within selected tolerances.

In still another illustrative embodiment, an automated sanding systemmay comprise a controller, a first end effector, a first robotic device,a second end effector, and a second robotic device. The controller maybe configured to identify a path over a surface of an object usingnumerical control data that was previously used to perform a number ofoperations on the surface of the object that created a number of surfacefeatures. The first end effector may include a dulling tool configuredfor use in dulling a reflective finish of the number of surfacefeatures. The first robotic device may be configured to move the firstend effector along the path identified. The first robotic device may befurther configured to position the dulling tool over each of the numberof surface features. The second end effector may comprise a laser deviceand a sanding tool. The laser device may be configured to generatefeedback laser data about the number of surface features after thereflective finish of the number of surface features has been dulled. Thesanding tool may be configured for use in sanding the number of surfacefeatures based on the feedback laser data until the number of surfacefeatures has been sanded to within selected tolerances. The secondrobotic device may be configured to move the second end effector alongthe path identified. The second robotic device may be further configuredto position the sanding tool and the laser device over the each of thenumber of surface features.

The features and functions can be achieved independently in variousembodiments of the present disclosure or may be combined in yet otherembodiments in which further details can be seen with reference to thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives and features thereof, will best be understood by reference tothe following detailed description of an illustrative embodiment of thepresent disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is an illustration of an isometric view of a sanding environmentin accordance with an illustrative embodiment;

FIG. 2 is an illustration of an enlarged view of a portion of a surfacein accordance with an illustrative embodiment;

FIG. 3 is an illustration of an enlarged isometric view of a firstrobotic device and a first end effector in accordance with anillustrative embodiment;

FIG. 4 is an illustration of an enlarged isometric view of a secondrobotic device in accordance with an illustrative embodiment;

FIG. 5 is an illustration of a sanding environment in accordance with anillustrative embodiment;

FIG. 6 is an illustration of an enlarged view of a rotating flap brushpositioned over a portion of a surface in accordance with anillustrative embodiment;

FIG. 7 is an illustration of a sanding environment with a first roboticdevice and a second robotic device moved to new positions in accordancewith an illustrative embodiment;

FIG. 8 is an illustration of an enlarged view of a sanding toolpositioned over a portion of a surface in accordance with anillustrative embodiment;

FIG. 9 is an illustration of a sanding environment with a first roboticdevice and a second robotic device moved to final positions inaccordance with an illustrative embodiment;

FIG. 10 is an illustration of a sanding environment in the form of ablock diagram in accordance with an illustrative embodiment;

FIG. 11 is an illustration of a process for sanding a number of surfacefeatures in the form of a flowchart in accordance with an illustrativeembodiment;

FIG. 12 is an illustration of a process for sanding a number of surfacemismatches on a surface of wing skin in the form of a flowchart inaccordance with an illustrative embodiment;

FIG. 13 is an illustration of a process for performing a sandingoperation on a surface mismatch in the form of a flowchart in accordancewith an illustrative embodiment;

FIG. 14 is an illustration of an aircraft manufacturing and servicemethod in the form of a block diagram in accordance with an illustrativeembodiment; and

FIG. 15 is an illustration of an aircraft in the form of a block diagramin which an illustrative embodiment may be implemented.

DETAILED DESCRIPTION

The illustrative embodiments recognize and take into account differentconsiderations. For example, the illustrative embodiments recognize andtake into account that it may be desirable to have a method andapparatus for automating the processing of blending surface mismatches.Further, the illustrative embodiments recognize and take into accountthat it may be desirable to have an automated sanding system capable ofworking on different types of surfaces, including surfaces that havereflective finishes.

The illustrative embodiments recognize and take into account that somecurrently available milling machines may be automated. For example, acomputer numerical control (CNC) milling machine is a type of automatedmilling machine. A computer numerical control milling machine may becontrolled by a computer using numerical control programming code. Theillustrative embodiments recognize and take into account that it may bedesirable to use the numerical control programming code used to guide amilling machine along a particular path to program an automated sandingsystem to follow substantially the same path.

Thus, the illustrative embodiments provide a method and apparatus forautomating the sanding of surface mismatches on objects, such as wingskins. Using the automated sanding system described by the illustrativeembodiments below may reduce the overall time and labor resources neededfor these types of sanding operations.

Referring now to the figures and, in particular, with reference to FIG.1, an illustration of an isometric view of a sanding environment isdepicted in accordance with an illustrative embodiment. As depicted,sanding environment 100 includes wing skin 102, first robotic device104, and second robotic device 106.

In this illustrative example, first end effector 108 is associated withfirst robotic device 104 and second end effector 110 is associated withsecond robotic device 106. As used herein, when one component is“associated” with another component, the association is a physicalassociation in the depicted examples.

For example, a first component, such as first end effector 108, may beconsidered to be associated with a second component, such as firstrobotic device 104, by being secured to the second component, bonded tothe second component, mounted to the second component, welded to thesecond component, fastened to the second component, and/or connected tothe second component in some other suitable manner. The first componentalso may be connected to the second component using a third component.Further, the first component may be considered to be associated with thesecond component by being formed as part of and/or as an extension ofthe second component.

As depicted, wing skin 102 may have surface 111. In this illustrativeexample, surface 111 may have a reflective finish. In other words,surface 111 may be a reflective surface. A milling machine (not shown inthis view) is used to perform cutting operations over surface 111 ofwing skin 102. The milling machine is a computer numerical control (CNC)milling machine in this illustrative example. Performing the cuttingoperations using this milling machine creates surface mismatches 112 onsurface 111. Surface mismatches 112 may take the form of, for example,raised or sharp edges on surface 111 of wing skin 102.

In this illustrative example, surface mismatches 112 may beout-of-tolerance. In other words, each of surface mismatches 112 mayhave one or more dimensions outside of selected tolerances. For example,each of surface mismatches 112 may be raised or extend past surface 111beyond some selected threshold. Surface mismatches 112 may need to bereworked to within selected tolerances. In particular, surfacemismatches 112 may need to be sanded down and smoothed. Moreparticularly, surface mismatches 112 may need to be blended with surface111 to within selected tolerances.

First end effector 108 may be used to dull the reflective finish on andaround each of surface mismatches 112. Dulling this reflective finishmay allow a laser device (not shown in this view) associated with secondend effector 110 to better measure surface mismatches 112. Second endeffector 110 may be used to sand each of surface mismatches 112 towithin selected tolerances based on feedback laser data from this laserdevice.

As depicted, surface mismatches 112 may be present on different portionsof surface 111. For example, a portion of surface mismatches 112 may bepresent on portion 114 of surface 111 of wing skin 102.

In this illustrative example, first robotic device 104 may be attachedto rail system 116, while second robotic device 106 may be attached torail system 118. Wing skin 102 has been positioned between these railsystems. First robotic device 104 may move in either direction alongaxis 120 on rail system 116 to move first end effector 108 relative towing skin 102. Similarly, second end effector 110 may move in eitherdirection along axis 122 on rail system 118 to move second end effector110 relative to wing skin 102.

As depicted, first robotic device 104 and second robotic device 106 arein initial position 124 and initial position 126, respectively. Theseinitial positions may be the positions at which first robotic device 104and second robotic device 106 begin when a wing, such as wing skin 102,is moved into a selected position between rail system 116 and railsystem 118. The process by which first robotic device 104 with first endeffector 108 and second robotic device 106 with second end effector 110are used to sand surface mismatches 112 on surface 111 of wing skin 102to within selected tolerances is described in the figures below.

With reference now to FIG. 2, an illustration of an enlarged view ofportion 114 of surface 111 from FIG. 1 is depicted in accordance with anillustrative embodiment. As depicted, set of surface mismatches 200 arepresent on portion 114 of surface 111. Set of surface mismatches 200 maybe a portion of surface mismatches 112 depicted in FIG. 1.

In this illustrative example, set of surface mismatches 200 may bealigned along path 202. Path 202 may be the path used by the millingmachine to perform cutting operations on portion 114 of surface 111.Surface mismatch 204 is an example of one of set of surface mismatches200. As depicted, surface mismatch 204 comprises a portion of surface111 being raised above the surrounding portion of surface 111. Surfacemismatch 204 may be sanded such that the portion of surface 111 includedin surface mismatch 204 may be blended with the portion of surface 111surrounding surface mismatch 204.

With reference now to FIG. 3, an illustration of an enlarged isometricview of first robotic device 104 and first end effector 108 from FIG. 1is depicted in accordance with an illustrative embodiment. As depicted,first end effector 108 includes attachment structure 300 and dullingtool 302. Attachment structure 300 is used to attach first end effector108 to first robotic device 104.

Dulling tool 302 takes the form of rotating flap brush 304 in thisillustrative example. In particular, rotating flap brush 304 may berotated about axis 306. Rotating flap brush 304 has outer surface 308.Outer surface 308 may have a texture configured to remove a finish, suchas the reflective finish on surface 111 of wing skin 102 in FIGS. 1-2.In this illustrative example, outer surface 308 may be an abrasivesurface.

As depicted, first robotic device 104 takes the form of robotic arm 310connected to base 312. Robotic arm 310 may be configured to move firstend effector 108, and thereby rotating flap brush 304, in a number ofdifferent directions. Base 312 is configured for attachment to railsystem 116 from FIG. 1.

With reference now to FIG. 4, an illustration of an enlarged isometricview of second robotic device 106 from FIG. 1 is depicted in accordancewith an illustrative embodiment. As depicted, second end effector 110includes attachment structure 400, sanding tool 402, laser device 404,and control box 405. Attachment structure 400 is used to attach secondend effector 110 to second robotic device 106.

Sanding tool 402 takes the form of sanding pad 406 in this illustrativeexample. Sanding pad 406 may have sanding surface 408 that may be usedfor sanding when sanding pad 406 is rotated about axis 410. Control box405 may include a control unit (not shown) that is used to control theoperation of sanding pad 406. The control unit may be, for example, aprocessor unit that controls a number of parameters that may include,but are not limited to, the rotational speed of sanding pad 406 aboutaxis 410, the number of turns completed for each surface mismatch beingsanded, the pressure applied to a surface by sanding pad 406, and othertypes of parameters.

The pressure applied to a surface by sanding pad 406 may be controlledby controlling the movement of sanding pad 406 in a direction along axis410. For example, sanding pad 406 may be moved down towards a surface toapply pressure to the surface.

In this illustrative example, laser device 404 is attached to controlbox 405. In this manner, laser device 404 is associated with second endeffector 110 by being part of second end effector 110. Laser device 404may be used to generate laser beam 412 that is used to measure a surfacemismatch. These laser measurements may be sent to the control unit andused by the control unit to generate one or more commands for secondrobotic device 106 and/or to adjust the operation of sanding pad 406.

As depicted, second robotic device 106 takes the form of robotic arm 414connected to base 416. Robotic arm 414 may be configured to move secondend effector 110, and thereby sanding pad 406, in a number of differentdirections. Base 416 is configured for attachment to rail system 118from FIG. 1.

With reference now to FIG. 5, an illustration of sanding environment 100from FIG. 1 is depicted in accordance with an illustrative embodiment.In this illustrative example, first robotic device 104 has been moved inthe direction of arrow 500 from initial position 124 in FIG. 1 toposition 502. In position 502, first robotic device 104 may positionrotating flap brush 304 over portion 114 of surface 111 such that thereflective finish on set of surface mismatches 200 may be dulled.

Turning now to FIG. 6, an illustration of an enlarged view of rotatingflap brush 304 positioned over portion 114 of surface 111 is depicted inaccordance with an illustrative embodiment. In particular, the enlargedview of rotating flap brush 304 positioned over portion 114 of surface111 is depicted taken with respect to lines 6-6 in FIG. 5.

First robotic device 104 is configured to guide rotating flap brush 304along path 202 based on the numerical control programming code that wasused to control the milling machine that performed cutting operationsalong path 202. In this illustrative example, first robotic device 104is configured to rotate rotating flap brush 304 in the direction ofarrow 600 about axis 306, while moving rotating flap brush 304 in thedirection of arrow 602 substantially along path 202. As rotating flapbrush 304 is moved in the direction of arrow 602, rotating flap brush304 contacts surface 111 and consequently, dulls the reflective finishon portion 114 of surface 111.

In particular, the reflective finish on set of surface mismatches 200and the portion of surface 111 surrounding set of surface mismatches 200is dulled. By dulling this reflective finish, rotating flap brush 304prepares this area for laser device 404 in FIG. 4. Laser device 404 maybe unable to take measurements of surface 111 with a desired level ofaccuracy when surface 111 is reflective.

With reference now to FIG. 7, an illustration of sanding environment 100from FIG. 1 with first robotic device 104 and second robotic device 106moved to new positions is depicted in accordance with an illustrativeembodiment. In this illustrative example, first robotic device 104 hascompleted dulling operations on portion 114 of surface 111 and has movedto position 700. Further, second robotic device 106 has been moved inthe direction of arrow 701 to position 702. In position 702, secondrobotic device 106 may position sanding pad 406 over portion 114 ofsurface 111 and set of surface mismatches 200 on portion 114 of surface111.

Turning now to FIG. 8, an illustration of an enlarged view of sandingtool 402 positioned over portion 114 of surface 111 is depicted inaccordance with an illustrative embodiment. In particular, the enlargedview of sanding tool 402 positioned over portion 114 of surface 111 isdepicted taken with respect to lines 8-8 in FIG. 7.

Second robotic device 106 is configured to guide sanding pad 406 alongpath 202 based on the numerical control programming code that was usedto control the milling machine that performed cutting operations alongpath 202. Second robotic device 106 rotates sanding pad 406 in thedirection of arrow 800 about axis 410, while moving sanding pad 406 inthe direction of arrow 802 substantially along path 202 to each of setof surface mismatches 200.

The control unit in control box 405 uses feedback laser data generatedby laser device 404 to control the operation, movement, and positioningof sanding pad 406 over each of set of surface mismatches 200 such thateach of set of surface mismatches 200 is sanded to within selectedtolerances.

With reference now to FIG. 9, an illustration of sanding environment 100from FIG. 1 with first robotic device 104 and second robotic device 106moved to final positions is depicted in accordance with an illustrativeembodiment. In this illustrative example, all sanding operations havebeen completed and all of surface mismatches 112 have been sanded downand blended with the rest of surface 111 to within selected tolerances.First robotic device 104 and second robotic device 106 have moved tofinal position 900 and final position 902, respectively.

Once wing skin 102 has been moved out of sanding environment 100, firstrobotic device 104 and second robotic device 106 may be moved back toinitial position 124 and initial position 126, respectively, from FIG.1, to perform sanding operations on a different wing. In this manner,the process of sanding surface mismatches on wing surfaces may beautomated.

The illustrations of sanding environment 100, wing skin 102, firstrobotic device 104, second robotic device 106, first end effector 108,and second end effector 110 in FIGS. 1-9 are not meant to imply physicalor architectural limitations to the manner in which an illustrativeembodiment may be implemented. Other components in addition to or inplace of the ones illustrated may be used. Some components may beoptional.

The different components shown in FIGS. 1-9 may be illustrative examplesof how components shown in block form in FIG. 10 below can beimplemented as physical structures. Additionally, some of the componentsin FIGS. 1-9 may be combined with components in FIG. 10, used withcomponents in FIG. 10, or a combination of the two.

With reference now to FIG. 10, an illustration of a sanding environmentis depicted in the form of a block diagram in accordance with anillustrative embodiment. Sanding environment 100 in FIG. 1 is an exampleof one manner in which sanding environment 1000 may be implemented. Asdepicted, sanding environment 1000 may be an environment in whichsanding operations may be performed on surface 1004 of object 1002. Inthis illustrative example, object 1002 takes the form of wing skin 1006.However, in other illustrative examples, object 1002 may take the formof some other type of object such as, but not limited to, a fuselageskin, a metal door, a metal plate, a spar, or some other type of object.

Number of surface features 1008 may be present on surface 1004. As usedherein, a “number of” items may include one or more items. In thismanner, number of surface features 1008 may include one or more surfacefeatures.

Number of surface features 1008 may take the form of number of surfacemismatches 1010 in this illustrative example. Number of surfacemismatches 1010 may have been created by cutting tool 1012. In oneillustrative example, cutting tool 1012 may be part of milling machine1014. In particular, milling machine 1014 may take the form of computernumerically controlled milling machine 1016. Cutting tool 1012 may havebeen controlled by milling machine 1014 to perform cutting operationsalong path 1018 on surface 1004 based on numerical control data 1019.Numerical control data 1019 may comprise numerical control programmingcode.

First end effector 1020 and second end effector 1022 may be used torework number of surface mismatches 1010 to within selected tolerances.In particular, first end effector 1020 may be used to perform first typeof operation 1021 on number of surface mismatches 1010, while second endeffector 1022 may be used to perform second type of operation 1023 onnumber of surface mismatches 1010.

As depicted, first end effector 1020 is associated with first roboticdevice 1024 and second end effector 1022 is associated with secondrobotic device 1026 in this illustrative example. First robotic device1024 and second robotic device 1026 may take the form of, for example,robotic arms.

First end effector 1020 may include dulling tool 1028. Dulling tool 1028is configured to perform dulling operation 1031, which includes dullingreflective finish 1030 on the portion of surface 1004 along path 1018.Dulling operation 1031 may be an example of first type of operation1021. In this manner, reflective finish 1030 on number of surfacemismatches 1010 and the portion of surface 1004 surrounding number ofsurface mismatches 1010 along path 1018 may be dulled. In oneillustrative example, dulling tool 1028 takes the form of rotating flapbrush 1034.

First robotic device 1024 may control the movement of first end effector1020. For example, first robotic device 1024 may be used to move andposition dulling tool 1028 of first end effector 1020 relative tosurface 1004. First robotic device 1024 may identify path 1018 alongwhich number of surface mismatches 1010 was formed based on numericalcontrol data 1019. First robotic device 1024 may move dulling tool 1028along path 1018 such that reflective finish 1030 of the portion ofsurface 1004 along path 1018 may be dulled by dulling tool 1028.

Second end effector 1022 may include sanding tool 1036. Sanding tool1036 is configured to perform sanding operation 1037, which includessanding number of surface mismatches 1010. Sanding operation 1037 is anexample of second type of operation 1023. In one illustrative example,sanding tool 1036 takes the form of sanding pad 1038.

Second robotic device 1026 may control the movement of second endeffector 1022. For example, second robotic device 1026 may be used tomove and position sanding tool 1036 of second end effector 1022 relativeto surface 1004. Second robotic device 1026 may identify path 1018 alongwhich number of surface mismatches 1010 was formed based on numericalcontrol data 1019. Second robotic device 1026 may move sanding tool 1036to each of number of surface mismatches 1010 such that each of number ofsurface mismatches 1010 may be sanded down to within selected tolerances1040.

In this illustrative example, sanding tool 1036 performs sandingoperation 1037 based on feedback laser data 1042 received from laserdevice 1044. Laser device 1044 may be associated with second endeffector 1022. In this illustrative example, laser device 1044 isconsidered part of second end effector 1022. However, in otherillustrative examples, laser device 1044 may be considered separate fromsecond end effector 1022.

Laser device 1044 is configured to generate feedback laser data 1042 bymeasuring each of number of surface mismatches 1010 as second endeffector 1022 is moved along path 1018. In this illustrative example,controller 1046 may receive feedback laser data 1042 and controloperation of sanding tool 1036 based on feedback laser data 1042. Forexample, controller 1046 may use feedback laser data 1042 to adjust anumber of parameters for sanding tool 1036. These parameters mayinclude, for example, without limitation, rotational speed, number ofturns, pressure applied to a surface, and/or other types of parameters.

In one illustrative example, controller 1046 is formed by first controlunit 1048 and second control unit 1050. First control unit 1048 may beimplemented within first robotic device 1024 and used to controloperation of first robotic device 1024 and first end effector 1020.

Second control unit 1050 may be implemented within one of second roboticdevice 1026 and second end effector 1022. In some cases, a portion ofsecond control unit 1050 may be implemented in second robotic device1026, while another portion of second control unit 1050 may beimplemented within second end effector 1022.

In this illustrative example, first robotic device 1024 and secondrobotic device 1026 may be programmed using numerical control data 1019such that first end effector 1020 and second end effector 1022,respectively, may be moved down a centerline of path 1018. However, inother illustrative examples, numerical control data 1019 may be used toidentify a modified path. This modified path may be offset from acenterline of path 1018 by some distance. This distance may be constantalong path 1018 or may vary along path 1018, depending on theimplementation. The modified path may then be used to guide first endeffector 1020 and second end effector 1022 along surface 1004 of object1002 instead of path 1018. The modified path may more accuratelyindicate the location of each of number of surface mismatches 1010.

The illustration of sanding environment 1000 in FIG. 10 is not meant toimply physical or architectural limitations to the manner in which anillustrative embodiment may be implemented. Other components in additionto or in place of the ones illustrated may be used. Some components maybe optional. Also, the blocks are presented to illustrate somefunctional components. One or more of these blocks may be combined,divided, or combined and divided into different blocks when implementedin an illustrative embodiment.

In some illustrative examples, number of surface features 1008 mayinclude a number of edges of object 1002. These edges may be the outeredges of object 1002. In these examples, first end effector 1020 and/orsecond end effector 1022 may be used to change the shape of these edges.As one illustrative example, rotating flap brush 1034 may be used tosmooth out the outer edges of object 1002. In this manner, rotating flapbrush 1034 may be used to perform other operations in addition todulling operation 1031.

The outer edges of object 1002 may be radiused to prepare surface 1004of object 1002 for, for example, a shot peening process. A shot peeningprocess involves impacting a surface with shot particles with sufficientforce to cause plastic deformation of surface 1004 of object 1002.However, when the shot particles impact a sharp edge, such as the outeredge of an object, the force of the shot particles may cause anundesired inconsistency to form at the edge of the object.

Consequently, it may be desirable to use rotating flap brush 1034 tosmooth out the edges of object 1002 prior to performing the shot peeningprocess. This type of smoothing of the edges may be referred to as “edgebreaking” or “edge radiusing.” Numerical control data 1019 may be usedto program first robotic device 1024 to move rotating flap brush 1034along the edges of object 1002 to smooth out or round out these edges.In this manner, an edge of object 1002 may be radiused using first endeffector 1020 based on numerical control data 1019 used to form object1002.

With reference now to FIG. 11, an illustration of a process for sandinga number of surface features is depicted in the form of a flowchart inaccordance with an illustrative embodiment. The process illustrated inFIG. 11 may be implemented in sanding environment 100 in FIG. 1.

The process may begin by performing a first type of operation on anumber of surface features on a surface of an object using a first endeffector (operation 1100). Feedback laser data may then be generatedabout the number of surface features after the first type of operationhas been performed using a laser device (operation 1102).

A second type of operation may be performed on the number of surfacefeatures using a second end effector and the feedback laser data torework the number of surface features until the number of surfacefeatures has been reworked to within selected tolerances (operation1104), with the process terminating thereafter.

With reference now to FIG. 12, an illustration of a process for sandinga number of surface mismatches on a surface of wing skin is depicted inthe form of a flowchart in accordance with an illustrative embodiment.The process illustrated in FIG. 12 may be implemented in sandingenvironment 100 in FIG. 1.

The process may begin by identifying a path over a surface of an objectusing numerical control data that was previously used to perform anumber of operations on the surface of the object that created a numberof surface features (operation 1200). A first end effector may be movedover the surface of the object along the path identified (operation1202). A reflective finish of each of the number of surface features maybe dulled using a dulling tool of the first end effector while movingthe first end effector along the path (operation 1204).

A second end effector may be moved over the surface of the object alongthe path identified (operation 1206). Feedback laser data may begenerated about the number of surface features using a laser deviceassociated with the second end effector while moving the second endeffector along the path identified (operation 1208). Each surfacefeature in the number of surface features may be sanded to withinselected tolerances using a sanding tool of the second end effector andthe feedback laser data generated by the laser device while moving thesecond end effector along the path identified (operation 1210), with theprocess then terminating thereafter.

With reference now to FIG. 13, an illustration of a process forperforming a sanding operation on a surface mismatch is depicted in theform of a flowchart in accordance with an illustrative embodiment. Theprocess illustrated in FIG. 13 may be implemented in sanding environment100 in FIG. 1. This process may be used to implement operations 1208 and1210 in FIG. 12.

The process begins by generating a mismatch measurement for a surfacefeature in a span-wise direction and in a chord-wise direction using alaser device (operation 1300). A determination may be made as to whetherthe mismatch measurement of the surface feature in either the span-wisedirection or the chord-wise direction is within selected tolerances(operation 1302).

If the mismatch measurement of the surface feature is within selectedtolerances in both the span-wise direction and the chord-wise direction,the process terminates. Otherwise, if the mismatch measurement of thesurface feature in either the span-wise direction or the chord-wisedirection is not within the selected tolerances, a sanding tool is usedto sand the surface feature to within the selected tolerances (operation1304), with the process then returning to operation 1300 as describedabove. In this manner, the surface feature that has been sanded may bereevaluated by generating another mismatch measurement for the surfacefeature.

Illustrative embodiments of the disclosure may be described in thecontext of aircraft manufacturing and service method 1400 as shown inFIG. 14 and aircraft 1500 as shown in FIG. 15. Turning first to FIG. 14,an illustration of an aircraft manufacturing and service method isdepicted in the form of a block diagram in accordance with anillustrative embodiment. During pre-production, aircraft manufacturingand service method 1400 may include specification and design 1402 ofaircraft 1500 in FIG. 15 and material procurement 1404.

During production, component and subassembly manufacturing 1406 andsystem integration 1408 of aircraft 1500 in FIG. 15 takes place.Thereafter, aircraft 1500 in FIG. 15 may go through certification anddelivery 1410 in order to be placed in service 1412. While in service1412 by a customer, aircraft 1500 in FIG. 15 is scheduled for routinemaintenance and service 1414, which may include modification,reconfiguration, refurbishment, and other maintenance or service.

Each of the processes of aircraft manufacturing and service method 1400may be performed or carried out by a system integrator, a third party,and/or an operator. In these examples, the operator may be a customer.For the purposes of this description, a system integrator may include,without limitation, any number of aircraft manufacturers andmajor-system subcontractors; a third party may include, withoutlimitation, any number of vendors, subcontractors, and suppliers; and anoperator may be an airline, a leasing company, a military entity, aservice organization, and so on.

With reference now to FIG. 15, an illustration of an aircraft isdepicted in the form of a block diagram in which an illustrativeembodiment may be implemented. In this example, aircraft 1500 isproduced by aircraft manufacturing and service method 1400 in FIG. 14and may include airframe 1502 with plurality of systems 1504 andinterior 1506. Examples of systems 1504 include one or more ofpropulsion system 1508, electrical system 1510, hydraulic system 1512,and environmental system 1514. Any number of other systems may beincluded. Although an aerospace example is shown, different illustrativeembodiments may be applied to other industries, such as the automotiveindustry.

Apparatuses and methods embodied herein may be employed during at leastone of the stages of aircraft manufacturing and service method 1400 inFIG. 14. In one illustrative example, components or subassembliesproduced in component and subassembly manufacturing 1406 in FIG. 14 maybe fabricated or manufactured in a manner similar to components orsubassemblies produced while aircraft 1500 is in service 1412 in FIG.14. As yet another example, one or more apparatus embodiments, methodembodiments, or a combination thereof may be utilized during productionstages, such as component and subassembly manufacturing 1406 and systemintegration 1408 in FIG. 14. One or more apparatus embodiments, methodembodiments, or a combination thereof may be utilized while aircraft1500 is in service 1412 and/or during maintenance and service 1414 inFIG. 14. The use of a number of the different illustrative embodimentsmay substantially expedite the assembly of and/or reduce the cost ofaircraft 1500.

The flowcharts and block diagrams in the different depicted embodimentsillustrate the architecture, functionality, and operation of somepossible implementations of apparatuses and methods in an illustrativeembodiment. In this regard, each block in the flowcharts or blockdiagrams may represent a module, a segment, a function, and/or a portionof an operation or step.

In some alternative implementations of an illustrative embodiment, thefunction or functions noted in the blocks may occur out of the ordernoted in the figures. For example, in some cases, two blocks shown insuccession may be executed substantially concurrently, or the blocks maysometimes be performed in the reverse order, depending upon thefunctionality involved. Also, other blocks may be added in addition tothe illustrated blocks in a flowchart or block diagram.

The description of the different illustrative embodiments has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different illustrativeembodiments may provide different features as compared to otherdesirable embodiments. The embodiment or embodiments selected are chosenand described in order to best explain the principles of theembodiments, the practical application, and to enable others of ordinaryskill in the art to understand the disclosure for various embodimentswith various modifications as are suited to the particular usecontemplated.

What is claimed is:
 1. A method comprising: performing a first type ofoperation on a number of surface features on a surface of an objectusing a first end effector; generating feedback laser data about thenumber of surface features after the first type of operation has beenperformed using a laser device; and performing a second type ofoperation on the number of surface features using a second end effectorand the feedback laser data to rework the number of surface featuresuntil the number of surface features has been reworked to withinselected tolerances.
 2. The method of claim 1, wherein performing thefirst type of operation comprises: dulling a reflective finish of asurface feature in the number of surface features using a dulling toolto allow the laser device to measure the surface feature and generatethe feedback laser data.
 3. The method of claim 2, wherein performingthe second type of operation comprises: sanding the surface featureusing a sanding tool and the feedback laser data until the surfacefeature has been sanded to within the selected tolerances.
 4. The methodof claim 1 further comprising: identifying a path over the surface ofthe object using numerical control data that was previously used toperform a number of operations on the surface of the object that createdthe number of surface features.
 5. The method of claim 4, whereinperforming the first type of operation comprises: moving the first endeffector over the surface of the object along the path identified; anddulling a reflective finish of each of the number of surface featuresusing a dulling tool of the first end effector while moving the firstend effector along the path.
 6. The method of claim 4, whereinperforming the second type of operation comprises: moving the second endeffector over the surface of the object along the path identified; andsanding each surface feature in the number of surface features to withinthe selected tolerances using a sanding tool of the second end effectorand the feedback laser data while moving the second end effector alongthe path.
 7. The method of claim 1, wherein generating the feedbacklaser data comprises: generating a mismatch measurement for a surfacefeature in the number of surface features in a span-wise direction andin a chord-wise direction using the laser device, wherein the surfacefeature is a surface mismatch.
 8. The method of claim 7, whereinperforming the second type of operation comprises: determining whetherthe mismatch measurement for the surface feature in either the span-wisedirection or the chord-wise direction is within selected tolerances; andsanding the surface feature using a sanding tool of the second endeffector in response to a determination that the mismatch measurementfor the surface feature in either the span-wise direction of thechord-wise direction is not within the selected tolerances.
 9. Themethod of claim 1 further comprising: radiusing an edge of the objectusing the first end effector based on numerical control data used toform the object.
 10. An apparatus comprising: a first end effectorconfigured to perform a first type of operation on a number of surfacefeatures on a surface of an object; a laser device configured togenerate feedback laser data about the number of surface features afterthe first type of operation has been performed; and a second endeffector configured to perform a second type of operation on the numberof surface features using the feedback laser data to rework the numberof surface features until the number of surface features has beenreworked to within selected tolerances.
 11. The apparatus of claim 10,wherein the first end effector comprises: a dulling tool configured todull a reflective finish of a surface feature in the number of surfacefeatures to allow the laser device to measure the surface feature andgenerate the feedback laser data.
 12. The apparatus of claim 11, whereinthe dulling tool is a rotating flap brush.
 13. The apparatus of claim11, wherein the second end effector comprises: a sanding tool configuredto sand the surface feature using the feedback laser data until thesurface feature has been sanded to within the selected tolerances. 14.The apparatus of claim 13, wherein the sanding tool is a sanding pad.15. The apparatus of claim 10 further comprising: a controllerconfigured to identify a path over the surface of the object usingnumerical control data that was previously used to perform a number ofoperations on the surface of the object that created the number ofsurface features.
 16. The apparatus of claim 15, wherein the controlleris configured to control a first robotic device to move the first endeffector over the surface of the object along the path identified. 17.The apparatus of claim 15, wherein the controller is configured tocontrol a second robotic device to move the second end effector over thesurface of the object along the path identified.
 18. The apparatus ofclaim 10, wherein the second end effector comprises: a control unitconfigured to receive the feedback laser data about a surface feature inthe number of surface features from the laser device and identify anumber of parameters for sanding the surface feature based on thefeedback laser data; and a sanding tool configured to sand the surfacefeature based on the number of parameters.
 19. The apparatus of claim10, wherein a surface feature in the number of surface features is asurface mismatch.
 20. An automated sanding system comprising: acontroller configured to identify a path over a surface of an objectusing numerical control data that was previously used to perform anumber of operations on the surface of the object that created a numberof surface features; a first end effector that includes a dulling toolconfigured for use in dulling a reflective finish of the number ofsurface features; a first robotic device configured to move the firstend effector along the path identified and position the dulling toolover each of the number of surface features; a second end effectorcomprising: a laser device configured to generate feedback laser dataabout the number of surface features after the reflective finish of thenumber of surface features has been dulled; and a sanding toolconfigured for use in sanding the number of surface features based onthe feedback laser data until the number of surface features has beensanded to within selected tolerances; and a second robotic deviceconfigured to move the second end effector along the path identified andposition the sanding tool and the laser device over the each of thenumber of surface features.